Handheld dimensioning system with feedback

ABSTRACT

A handheld dimensioning system that analyzes a depth map for null-data pixels to provide feedback is disclosed. Null-data pixels correspond to missing range data and having too many in a depth map may lead to dimensioning errors. Providing feedback based on the number of null-data pixels helps a user understand and adapt to different dimensioning conditions, promotes accuracy, and facilitates handheld applications.

FIELD OF THE INVENTION

The present invention relates to dimensioning systems, and inparticular, to a handheld dimensioning system that can provide feedbackrelating to the quality of data used for a dimension measurement.

BACKGROUND

Hands-free measurements of an object's dimensions (e.g., volume) may becarried out using a dimensioning system. Dimensioning systems cancompute a package's volume to facilitate its storage, handling,transporting, and/or invoicing. Most transport vehicles have both volumeand weight capacity limits, and an inefficient use of space results ifthe transport vehicle becomes full before its weight capacity isreached. By dimensioning packages, shipping companies can fill spaceoptimally and compute shipping charges accurately. For this reason,dimensioning systems that accurately gather volume information, withoutcausing disruptions in workflow, are highly desirable.

Handheld dimensioners require no dedicated setup to measure a dimension.These devices are small (e.g., fit into a user's hand) and convenientsince the dimensioner is mobile. The handheld dimensioner can bepositioned in a wide variety of environments. These environments mayvary considerably because of lighting, object positioning, and/or objectcoloring. Some environments are not suitable for dimensioning; however,this is not always obvious to a user.

A need, therefore, exists for a handheld dimensioning system configuredto (i) analyze the quality of the data used for dimensioning and (ii)provide feedback regarding this data, especially where dimensioningerrors might otherwise result.

SUMMARY

Accordingly, in one aspect, the present invention embraces a method forobtaining a dimension measurement using a handheld dimensioner. Themethod includes the step of using a processor to receive range data froma dimensioning subsystem. From the range data, a processor creates adepth map. The depth map is analyzed, using the processor, to determinethe depth map's null-data pixel count, wherein the null-data pixel countis the sum total of the null-data pixels. If the null-data pixel countis at or below a threshold count, then the processor computes adimension measurement. Alternatively, if the null-data pixel-count isabove the threshold count, then the processor generates an errorfeedback.

In an exemplary embodiment, the processor generates a confidencefeedback if the depth-map's null-data pixel count is below the thresholdcount. An exemplary confidence feedback is a visible image of thehandheld dimensioner's field-of-view including a wireframe rendering ofan object. Another exemplary confidence feedback is a confidence valuecorresponding to the null-data pixel count. Yet another exemplaryconfidence feedback indicates that the dimension measurement conforms toa standard.

In another exemplary embodiment, the processor generates a user-guidancefeedback if the null-data pixel count is above the threshold count. Anexemplary user-guidance feedback is information to facilitate theadjustment of a measurement geometry. Another exemplary user-guidancefeedback embodiment is information to facilitate the adjustment oflighting.

In another aspect, the present invention embraces a handhelddimensioning system configured to provide error feedback. Thedimensioning system includes a dimensioning subsystem with at least oneimage sensor for capturing range data of an object or objects within afield-of-view. The dimensioning system also includes a control subsystemcommunicatively coupled to the at least one image sensor. The controlsubsystem includes at least one processor and at least onenon-transitory storage medium for storing information andprocessor-executable instructions. The processor-executable instructionsconfigure the processor to perform several functions. The processor isconfigured to receive range data from the dimensioning subsystem and tocreate a depth map from the range data. The processor is then configuredto processes the depth map to obtain a depth-map quality. If thedepth-map quality is below a minimum quality threshold, then theprocessor is configured to generate an error feedback.

In an exemplary embodiment, the depth-map quality includes a sum of thenumber of pixels in the depth map having insufficient information todetermine depth.

In another exemplary embodiment, the handheld dimensioning systemincludes a pattern projector to project a light pattern onto the objector objects in the field-of-view.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an image of an exemplary depth map.

FIG. 2 depicts an exemplary feedback including a visible image of anobject and a wireframe rendering of the object.

FIG. 3 schematically depicts an exemplary measurement geometry.

FIG. 4 schematically depicts a flowchart of an exemplary method forobtaining a dimension measurement using a handheld dimensioner.

FIG. 5 schematically depicts an exemplary handheld dimensioning systemconfigured to provide error feedback.

DETAILED DESCRIPTION

The present invention embraces a handheld dimensioning system (i.e.,dimensioner) that provides feedback regarding the quality of the rangedata used for dimensioning. This qualitative feedback is especiallyimportant in handheld dimensioning.

Handheld dimensioning is a challenging problem. In handheld dimensioningapplications, the measurement environment is uncontrolled, and thedimensioner must accommodate a wide range of measurement conditions.These measurement conditions include diverse lighting conditions,measurement geometries (e.g., spatial relationships and orientations),and/or object colors.

Handheld applications typically have a low tolerance for excessivemeasurement times and/or alignment complexities. A handheld dimensionermust employ robust sensing technologies with quality assurance feedbackto achieve reliable measurements in adverse measurement conditions.

A variety of sensing technologies have been employed for dimensioning(e.g., time-of-flight sensing or stereoscopic imaging) to capture rangedata (i.e., depth data). One exemplary sensing technology, well suitedfor handheld dimensioners, uses structured light to capture range data.Structured-light dimensioners sense depth by projecting a known lightpattern (e.g., dots, grids, bars, stripes, checkerboard, etc.) onto ascene (i.e., field-of-view). A pattern image is captured by an imagesensor laterally offset from the projector. Distortions in the reflectedlight pattern caused by objects in the field-of-view are analyzed toderive depth (i.e., range) information.

A handheld-dimensioner's dimensioning subsystem may use structured lightto sample spatially the range between the dimensioning system and anobject (or objects) within the field-of-view. These samples combine toform a two dimensional (2D) array of range data. This range data is usedto create a depth map.

A typical depth map is shown in FIG. 1. The depth map 1 is atwo-dimensional digital image wherein the pixel values correspond to thesampled range. For the exemplary depth map in FIG. 1, close (i.e.,short-range) pixels are lighter, while far (i.e., long range) pixels aredarker.

Some pixels in the depth map 1 are black. These black pixels representnull-data pixels 2. Null-data pixels are points in the field-of-viewthat provided insufficient information to determine depth (i.e., range).Black null-data pixels are shown in the depth map 1; however, any pixelvalue could represent null-data pixels 2.

A variety of measurement conditions cause null-data pixels. One suchcondition is lighting. Suitable lighting is necessary to capture imagesof the light pattern used in structured-light dimensioners. Too littlelight may lead to noisy images, while excessive light may lead tosaturated images. The lighting must also be uniform. Images with darkareas and saturated areas may have null-data pixels in both, since thedynamic range of the image sensor is often too small to capture bothideally.

The depth map 1 in FIG. 1 has null-data pixels 2 along some edges and onthe largest object surface shown. FIG. 2 shows visual feedback of theobject. The feedback includes a visible image 3 of the object and showsthat the source of the null-data pixels 2 is the darkly colored printing4 on the side of the object. The printing 4 is reflects light poorly,leading to a low-light imaging condition. The light pattern (in thisarea) cannot be imaged to determine range. These pixels are assigned azero value (i.e., null-data pixels). Object color can cause null-datapixels 2, and is a fact that may not be obvious without evaluating thedepth map.

Certain measurement geometries can also lead to null-data pixels 2. Heremeasurement geometry refers to the measurement setup (e.g., spatialrelationships and/or orientations). FIG. 3 depicts an exemplarymeasurement geometry. An object 5 for dimensioning is placed within adimensioning system's 6 field-of-view 7. The object 5 is positioned at arange 8 (i.e., the distance between the dimensioning system and theobject). Typically, three sides of the object are visible (to thedimensioner) for volume measurements. A surface 11 is visible when twoof its edges 9,10 create an angle 12 (i.e., an angle with respect to thedimensioner's optical axis) that is greater than zero. Larger angles 12imply more surface visibility. Feedback to facilitate the positioning ofan object (or dimensioner) to maximize surface visibility is helpful inobtaining accurate dimensioning results.

When using a structured light dimensioner, an object's side must reflectsome minimum portion of the projected light pattern to convey depthinformation (i.e., range data). For the measurement geometry in FIG. 3,the object 5 can be rotated 13 to adjust the angle 12 so that a surface11 reflects more of the projected light pattern. Without feedback, itmay be difficult to make this adjustment.

Feedback is necessary to quantify the quality of the depth map. Thedepth-map quality is typically determined by quantifying the number ofnull-data pixels in the depth map (i.e., null-data pixel-count). Forexample, the null-data pixel-count is the sum of the null-data pixels ina depth map.

The null-data pixel-count may determine the feedback type. If thenull-data pixel-count is above a threshold count, then the processor maygenerate an error feedback. In another exemplary embodiment, if theratio of the null-data pixel-count to the total number of pixels for asurface is higher than a threshold (e.g., 10%), then error feedback maybe generated. Error feedback may indicate that the depth map is notsuitable for dimensioning and could cause a measurement error orinaccuracy.

When the dimensioning system employs a time-of-flight sensor to generatethree-dimensional data, the depth map is replaced with a distance mapbut the functionality is the same. Here each distance-map pixel may beassigned a confidence value. This confidence value may be averaged overthe image or over a surface within the image. If the average confidencevalue over a prescribed area is below a threshold (e.g., 80%) then theprocessor may generate an error feedback. The error feedback mayindicate that the distance map is not suitable for dimensioning andcould cause a measurement error or inaccuracy.

Error feedback may include an indication that the handheld dimensionercannot produce a dimension measurement under the current conditions.Error feedback may also include an indication that at least one objectsurface is not visible. In another embodiment, the error feedback mayinclude an indication that the object color is too dark or that thelighting is insufficient. In some embodiments user-guidance feedback isprovided in addition to (or instead of) error feedback whenever thethreshold count is exceeded.

User-guidance feedback provides information to facilitate the adjustmentof the measurement setup to improve the depth-map's quality.User-guidance feedback may indicate an adjustment to the measurementgeometry (e.g., “rotate object” or “move dimensioner up”). User-guidancefeedback may also specify an adjustment to the handheld-dimensioner'ssettings (e.g., “change shutter speed”). In another exemplaryembodiment, the user-guidance feedback may include information tofacilitate the adjustment of lighting.

After complying with the user-guidance feedback, a user may take anotherdimension measurement. A new depth map is then created, evaluated, andcompared to the threshold count. This process could repeat until thedepth map's null-data pixel count is at, or below, the threshold count.

Alternatively, this repetition could end after some fixed number oftrials.

If the depth map's null-data pixel-count is at or below the thresholdcount then the depth-map quality is suitable for dimensioning. Theprocessor uses the depth map to compute a dimension measurement. Aconfidence feedback may also be generated.

Confidence feedback may include a visible image of thehandheld-dimensioner's field-of-view and a wireframe rendering of theobject created from range data. This confidence feedback is shown inFIG. 2. In this example, the wireframe rendering 15 matches the object5, and in this way, helps provide confirmation that the dimensioningmeasurement is valid.

The confidence feedback could also include a confidence value. Theconfidence value could, for example, correspond to the percentage ofnull-data pixels (e.g., [100%−null-data-pixel %]=confidence %). Usingthis approach, a confidence value of 100% is a perfect depth map (i.e.,with no null-data pixels), while a confidence value of 0% wouldrepresent the worst possible depth map.

In another embodiment, the confidence feedback indicates the dimensionmeasurement's conformance to a standard. Industry standards promotehealthy business and consumer climates by providing specifications toinsure uniform and equitable measurements. Standards may require aparticular measurement accuracy. The confidence feedback could indicatethat a dimension measurement meets the requirements stipulated in one ormore industry standards.

The feedback types describe so far (i.e., user-guidance feedback, errorfeedback, or confidence feedback) could each include indicationsembodied in a variety of forms. Audio or visible messages could conveythe feedback. Audio feedback could include sounds or voice commands.Visible feedback could include illuminated indicators and/orgraphics/text displayed on a screen.

FIG. 4 illustrates an exemplary a dimensioning measurement methodincluding feedback based on a depth-map quality assessment. A handhelddimensioner is used obtain a dimension measurement. Range data iscollected by a dimensioning subsystem that (in one possible embodiment)projects an infrared (IR) light pattern onto an object. The methodbegins with handheld dimensioner's processor receiving range data fromthe dimensioning subsystem 20. The processor then creates a depth mapfrom the range data 25. This depth map may have null-data pixels. In thenext step, the processor determines a null-data pixel-count 30 (i.e.,summates the null-data pixels). The processor then compares thenull-data pixel-count to a stored threshold count 35. This thresholdcount is based on a variety of factors that vary with application. Thethreshold count may be stored in the handheld dimensioner's memory andmay be adjusted to meet the requirements associated with differentapplications.

If the null-data pixel-count is less than or equal to the thresholdcount, then the processor may compute a dimension measurement 40. Insome embodiments, confidence feedback may be generated 45 and presentedseparately, or with, the dimension measurement.

If the null-data pixel count is greater than the threshold count, thenthe processor may (in some embodiments) use information derived from thedepth map to generate user-guidance feedback 50. This user-guidancefeedback facilitates the adjustment of the dimensioner, the environment,and/or the object for an improved range data acquisition. Acquiringrange data, creating a depth map, and comparing the null-data in thedepth map to a threshold count may repeat until a depth map withsufficient quality is obtained.

Error feedback may be generated 55 if the null-data pixel count isgreater than the threshold count. This error feedback helps to alert theuser that the data acquired is not suitable for a dimensioningmeasurement.

FIG. 5 schematically depicts a block diagram of an exemplary handhelddimensioning system configured to provide error feedback. An object 5positioned in front of the dimensioning system 6 may have its dimensions(e.g., volume) measured optically. The dimensioner 6 utilizes a varietyof subsystems to measure the object.

A dimensioning subsystem 6 uses at least one image sensor to capturerange data of an object or objects within a field-of-view 7. Toaccomplish this, the dimensioning subsystem 60 uses an imaging lens 61to focus a real image of the field-of-view 7 onto an image sensor 62 toconvert the optical image into an electronic signal. The image sensor 62may be a charge coupled device (i.e., CCD) or a sensor usingcomplementary metal oxide semiconductor (i.e., CMOS) technology. Theimage sensor 62 typically includes a plurality of pixels that sample thereal image and convert the real-image intensity into an electronicsignal. A digital signal processor (i.e., DSP) 63 is typically includedto facilitate the formation of the digital image.

The creation of range data (i.e., depth information) is facilitated by asecond element in the dimensioning subsystem that either transmits anoptical signal (i.e., projector) or images a scene (i.e., sensor). Thelens 64 for the projector (or sensor) 65 is typically configured into astereo arrangement with the imaging lens 61 to allow for the collectionof depth information (e.g., using the principle of parallax). Theprojector (or sensor) 65 is typically communicatively coupled to the DSP63 which may facilitate its control and communication.

A control subsystem 70 is communicatively coupled to the at least oneimage sensor (or the image sensor 61 and the projector 65) via the DSP63. The control subsystem 70 includes one or more processors 71 (e.g.,one or more controller, digital signal processor (DSP), applicationspecific integrated circuit (ASIC), programmable gate array (PGA),and/or programmable logic controller (PLC)) to configure the imagingsubsystem for the dimensioning data collection and to perform theprocessing to generate dimensioning measurements and feedback. Theprocessor 71 may be configured by processor-executable instructions(e.g., a software program) stored in at least one non-transitory storagemedium (i.e., memory) 72 (e.g., read-only memory (ROM), flash memory,and/or a hard-drive). The processor-executable instructions, whenexecuted by the processor 71 configure the processor to: (i) receiverange data from the dimensioning subsystem, (ii) create a depth map fromthe range data, (iii) process the depth map to obtain a depth-mapquality, and (iv) generate an error feedback if the depth-map quality isbelow a minimum-quality threshold.

The dimensioning system 6 may also include a user-interface subsystem 80to display dimension measurements (e.g., linear dimension or volume) andfeedback. In some embodiments, the user-interface subsystem 80 may alsofacilitate the selection of objects and/or surfaces for dimensioning.

The dimensioner 6 may also include a communication subsystem 90 fortransmitting and receiving information to/from a separate computingdevice or storage device. This communication subsystem 90 may be wiredor wireless and may enable communication via a variety of protocols(e.g., IEEE 802.11, including WI-FI®, BLUETOOTH®, CDMA, TDMA, or GSM).

The subsystems in the dimensioner 6 are electrically connected via acouplers (e.g., wires or fibers) to form an interconnection subsystem100. The interconnection system 100 may include power buses or lines,data buses, instruction buses, address buses, etc., which allowoperation of the subsystems and interaction there between.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1. A method for obtaining a dimension measurement using a handhelddimensioner, the method comprising: receiving, using a processor, rangedata from a dimensioning subsystem; creating, using the processor, adepth map from the range data; determining, using the processor, anull-data pixel-count from the depth map, the null-data pixel-countcomprising a sum total of null-data pixels; and computing, using theprocessor, a dimension measurement if the null-data pixel-count is at orbelow a threshold count, or generating, using the processor, an errorfeedback if the null-data pixel-count is above the threshold count. 2.The method according to claim 1, wherein the depth map comprises adigital image of the handheld-dimensioner's field-of-view, wherein thedigital-image's pixel values correspond to the distance between thehandheld dimensioner and an object or objects in the field-of-view. 3.The method according to claim 2, wherein the depth map's null-datapixels comprise a single pixel value, the single pixel value indicatingthat a range measurement for a pixel was not possible.
 4. The methodaccording to claim 1, comprising generating, using the processor, aconfidence feedback if the depth-map's null-data pixel-count is belowthe threshold count.
 5. The method according to claim 4, wherein theconfidence feedback comprises a visible image of thehandheld-dimensioner's field-of-view and a wireframe rendering of anobject, the wireframe rendering displayed with the visible image.
 6. Themethod according to claim 4, wherein the confidence feedback comprisesan indication of a confidence value, the confidence value correspondingto the null-data pixel count.
 7. The method according to claim 4,wherein the confidence feedback comprises an indication of the dimensionmeasurement's conformance to a standard.
 8. The method according toclaim 1, comprising generating, using the processor, a user-guidancefeedback if the null-data pixel-count is above the threshold count. 9.The method according to claim 8, wherein the user-guidance feedbackcomprises information to facilitate the adjustment of a measurementgeometry.
 10. The method according to claim 8, wherein the user-guidancefeedback comprises information to facilitate the adjustment of lighting.11. The method according to claim 8, comprising repeating the receiving,creating, determining, and generating until the depth map's null-datapixel-count is at or below the threshold count then computing, using theprocessor, a dimension measurement.
 12. The method according to claim 1,wherein the error feedback comprises an indication that the handhelddimensioner cannot produce a dimension measurement.
 13. The methodaccording to claim 1, wherein the error feedback comprises an indicationthat the object or objects are positioned with at least one objectsurface that is not visible to the handheld dimensioner.
 14. The methodaccording to claim 1, wherein the error feedback comprises an indicationthat the object color is too dark or that the lighting is insufficient.15. A handheld dimensioning system configured to provide error feedback,the dimensioning system comprising: a dimensioning subsystem comprisingat least one image sensor for capturing range data of an object orobjects within a field-of-view; and a control subsystem communicativelycoupled to the at least one image sensor, the control subsystemcomprising at least one processor and at least one non-transitorystorage medium for storing information and processor-executableinstructions, wherein the processor-executable instructions configurethe processor to: (i) receive range data from the dimensioningsubsystem, (ii) create a depth map from the range data, (iii) processthe depth map to obtain a depth-map quality, and (iv) generate an errorfeedback if the depth-map quality is below a minimum-quality threshold.16. The handheld dimensioning system according to claim 15, wherein thedepth-map quality comprises a sum of the number of pixels in the depthmap having insufficient information to determine depth.
 17. The handhelddimensioning system according to claim 15, wherein the dimensioningsubsystem comprises a pattern projector, the pattern projectorprojecting a light pattern on the object or objects in thefield-of-view.
 18. The handheld dimensioning system according to claim15, wherein the error feedback comprises user guidance information tofacilitate the repositioning of the handheld dimensioner to capturerange data having an improved depth-map quality.
 19. The handhelddimensioning system according to claim 15, wherein the error feedbackcomprises information indicating that no dimension measurement ispossible.
 20. The handheld dimensioning system according to claim 15,wherein the error feedback comprises information indicating that adimension measurement does not conform to a standard.